The document discusses using Taguchi methods and design of experiments to optimize CNC EDM and WEDM process parameters. It describes selecting input factors like voltage, current, pulse on time and responses like material removal rate and machining time. Orthogonal arrays are used to design the experiments. Signal to noise ratios are calculated to analyze the experimental results and determine the most influential factors for both processes. The analysis found that voltage has the largest effect on material removal rate for EDM and voltage and current most affect machining time for EDM and WEDM respectively.
Optimization of process parameters of WEDM for machining of monel r-405 mater...Pinkraj Gangwar
This thesis presents an optimization of process parameters for wire EDM machining of Monel R-405 material. Experiments were conducted varying pulse on time, pulse off time, peak current, servo voltage, and wire feed rate. Response surface methodology was used to develop models for material removal rate (MRR) and surface roughness (SR). ANOVA showed pulse on time was the most influential parameter for both MRR and SR. Multi-objective optimization using NSGA-II identified a Pareto optimal front of parameter combinations that maximized MRR and minimized SR.
Optimization of tig welding using taguchi and regression analysisvivek bisht
In order to reduce the no of experiments required for finding the output .here we use these mathematically process in order to find output (in our case it is STRENGTH). without using further experiments
OPTIMIZATION OF MACHINING PARAMETERS WITH TOOL INSERT SELECTION FOR S355J2G3 ...AVINASH JURIANI
The key goal of modern manufacturing industries is increased productivity & high quality
Surface Roughness is major concern for quality aspects affecting performance.
Speed, Feed & Depth of cut mainly influences SR & MRR in Turning
Taguchi & Grey Relational Technique is used for optimization followed by ANOVA for contribution
MADM is the need for better Tool Insert Selection to get requisite surface finish
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
Effect and optimization of machining parameters on cutting force and surface ...eSAT Journals
Abstract Productivity and the quality of the machined parts are the main challenges of metal cutting industry during turning process. Therefore cutting parameters must be chosen and optimize in such a way that the required surface quality can be controlled. Hence statistical design of experiments (DOE) and statistical/mathematical model are used extensively for optimize. The present investigation was carried out for effect of cutting parameters (cutting speed, depth of cut and feed) In turning off mild steel and aluminum to achieve better surface finish and to reduce power requirement by reducing the cutting forces involved in machining. The experimental layout was designed based on the 2^k factorial techniques and analysis of variance (ANOVA) was performed to identify the effect of cutting parameters on surface finish and cutting forces are developed by using multiple regression analysis. The coefficients were calculated by using regression analysis and the model is constructed. The model is tested for its adequacy by using 95% confidence level. By using the mathematical model the main and interaction effects of various process parameters on turning was studied. Keywords: Universal Lathe, Surface Finish, Cutting Force, High Speed Steel Tool, Factorial Technique.
Multi-Objective Optimization of EDM process parameters using Taguchi-Grey Rel...IRJET Journal
This document presents a study that uses Taguchi-Grey Relational Analysis to optimize the EDM process parameters for aluminum work material with a copper electrode. The objectives are to maximize the material removal rate and minimize the tool wear rate and surface roughness. Experiments are conducted with four machining parameters (discharge current, pulse on time, flushing pressure, and polarity) each at two levels. Response data is analyzed using Grey Relational Analysis to determine the optimal parameter combination and ranking. The optimal levels found are discharge current of 16A, pulse on time of 1010 μs, flushing pressure of 5kgf/cm2, and normal polarity. Analysis of variance indicates that discharge current has the most significant influence on the output responses
Optimization of process parameters of WEDM for machining of monel r-405 mater...Pinkraj Gangwar
This thesis presents an optimization of process parameters for wire EDM machining of Monel R-405 material. Experiments were conducted varying pulse on time, pulse off time, peak current, servo voltage, and wire feed rate. Response surface methodology was used to develop models for material removal rate (MRR) and surface roughness (SR). ANOVA showed pulse on time was the most influential parameter for both MRR and SR. Multi-objective optimization using NSGA-II identified a Pareto optimal front of parameter combinations that maximized MRR and minimized SR.
Optimization of tig welding using taguchi and regression analysisvivek bisht
In order to reduce the no of experiments required for finding the output .here we use these mathematically process in order to find output (in our case it is STRENGTH). without using further experiments
OPTIMIZATION OF MACHINING PARAMETERS WITH TOOL INSERT SELECTION FOR S355J2G3 ...AVINASH JURIANI
The key goal of modern manufacturing industries is increased productivity & high quality
Surface Roughness is major concern for quality aspects affecting performance.
Speed, Feed & Depth of cut mainly influences SR & MRR in Turning
Taguchi & Grey Relational Technique is used for optimization followed by ANOVA for contribution
MADM is the need for better Tool Insert Selection to get requisite surface finish
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
Effect and optimization of machining parameters on cutting force and surface ...eSAT Journals
Abstract Productivity and the quality of the machined parts are the main challenges of metal cutting industry during turning process. Therefore cutting parameters must be chosen and optimize in such a way that the required surface quality can be controlled. Hence statistical design of experiments (DOE) and statistical/mathematical model are used extensively for optimize. The present investigation was carried out for effect of cutting parameters (cutting speed, depth of cut and feed) In turning off mild steel and aluminum to achieve better surface finish and to reduce power requirement by reducing the cutting forces involved in machining. The experimental layout was designed based on the 2^k factorial techniques and analysis of variance (ANOVA) was performed to identify the effect of cutting parameters on surface finish and cutting forces are developed by using multiple regression analysis. The coefficients were calculated by using regression analysis and the model is constructed. The model is tested for its adequacy by using 95% confidence level. By using the mathematical model the main and interaction effects of various process parameters on turning was studied. Keywords: Universal Lathe, Surface Finish, Cutting Force, High Speed Steel Tool, Factorial Technique.
Multi-Objective Optimization of EDM process parameters using Taguchi-Grey Rel...IRJET Journal
This document presents a study that uses Taguchi-Grey Relational Analysis to optimize the EDM process parameters for aluminum work material with a copper electrode. The objectives are to maximize the material removal rate and minimize the tool wear rate and surface roughness. Experiments are conducted with four machining parameters (discharge current, pulse on time, flushing pressure, and polarity) each at two levels. Response data is analyzed using Grey Relational Analysis to determine the optimal parameter combination and ranking. The optimal levels found are discharge current of 16A, pulse on time of 1010 μs, flushing pressure of 5kgf/cm2, and normal polarity. Analysis of variance indicates that discharge current has the most significant influence on the output responses
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
MULTIOBJECTIVE OPTIMIZATION OF MACHINING PARAMETERSFOR C-65 MATERIAL USING TA...AVINASH JURIANI
CNC machines lead a major in a manufacturing industry, machining comprises of wide variety of operations with turning operation being the most important one. In turning operation performance specifications of concern include surface
finish, material removal rate& tolerance which are mostly affected by different
machining parameters like machining condition, work piece, tool geometry and
operating parameters. Among all of them operating parameter and tool
geometry is the most important parameter for better surface finish. This
project presents the optimization of various operating parameters as velocity,
feed and depth of cut for proper selection of tool inserts for surface finish. The
experiment was conducted on CNC lathe with C-65 shaft material. Taguchi’s
statistical analysis was employed for single optimization as it provides an
effective method for product designing which operate continuously over
varying conditions surface roughness and depth of cut is the most effective
parameter for material removal rate. Best parameter combinations for
optimum surface roughness are speed (A) at level 2 (191 m/min), feed (B)
at level 1 (0.2 mm/rev), depth of cut (C) at level 3 (1.5 mm), for optimum
material removal rate are speed (A) at level 3 (254 m/min), feed (B) at level 3
(0.3 mm/rev), depth of cut (C) at level 3 (1.5 mm). GRG optimum
parameters for SR and MRR are Speed (A) at level 2 (191 m/min), feed (B)
at level 1 (0.2 mm/rev), depth of cut (C) at level 3 (1.5 mm)
Optimization of Process Parameters of Powder Mixed Dielectric EDM for MRR and RaIRJET Journal
This document presents an experimental study on optimizing process parameters for powder mixed dielectric electric discharge machining (PMEDM) to maximize material removal rate (MRR) and minimize surface roughness (Ra). Taguchi methodology was used to design experiments using an L9 orthogonal array with discharge current, duty factor, spark gap, and graphite powder concentration as input variables. Regression analysis and grey relational analysis were conducted on the experimental results. The optimal parametric combination found was discharge current of 20A, duty factor of 5%, spark gap of 0.05mm, and graphite powder concentration of 6g/l, achieving a predicted MRR of 68.43mm3/min and Ra of 7.28μm,
This document summarizes a study that used the Taguchi method to analyze the effect of parameters like voltage, current, and pulse on time on material removal rate (MRR) and surface roughness (SR) during CNC EDM of SK-5 material. Experiments were conducted based on an L9 orthogonal array with 3 factors at 3 levels. Analysis found voltage had the largest effect on MRR while pulse on time most influenced SR. The optimized parameters were experiment 4 for MRR and experiment 7 for SR. In conclusion, the Taguchi method helped determine the best settings of CNC EDM parameters for machining SK-5.
Experimental Investigations to Study the Impact of Machining Parameters on Mi...IJERA Editor
Plasma arc cutting is extensively used to cut steels and aluminum. Plasma arc cutting was invented in 1950‟s and since then, it became commercial on its advent into the industry. The purpose of this research is to ascertain the influence of various parameters on plasma arc cutting process while machining mild steel. The experiments were conducted using Taguchi L16 orthogonal array with current, voltage, speed, plate thickness as the control parameters and surface roughness, kerf as the response variables. The optimal parameter setting for the machining process is determined by conducting a Grey-Taguchi method. Orthogonal array L16 (4 power 4) of Taguchi, Signal to Noise ratio, the Analysis of Variance(ANOVA) are employed to find the optimal levels and to analyze the optimum levels and to analyze the impact of current, voltage, speed, plate thickness on kerf and surface roughness.
IRJET- Experimental Investigation for Effect of Vibration on Mechanical Prope...IRJET Journal
This document investigates the effect of vibration on the mechanical properties of Duplex Stainless Steel (DSS) 2205 during Tungsten Inert Gas (TIG) welding. Nine experimental welds were conducted using parameters of welding current, torch tilt angle, and vibration motor speed based on Taguchi's design of experiments. Tensile strength and hardness were evaluated for each weld. Results showed that applying vibration during welding increased tensile strength and hardness compared to welding without vibration. The optimal parameters were a welding current of 80 amps, torch tilt angle of 90 degrees, and vibration motor speed of 1500 RPM, which produced a weld with the highest tensile strength of 855 MPa. In conclusion,
The document discusses the implementation of the Taguchi method to optimize process parameters for maximizing the material removal rate (MRR) in electrical discharge machining (EDM). Key process parameters analyzed include peak current, pulse on time, pulse off time, tool material, and workpiece material. Experiments were conducted using a Taguchi L27 orthogonal array with three levels for each parameter. Analysis of variance of the signal-to-noise ratios revealed that current has the most significant effect on MRR, followed by pulse on time, pulse off time, and tool material. The optimal parameters determined for maximum MRR were a peak current of 20A, pulse on time of 8μs, pulse off time of 5μs, using
Experimental Analysis and Optimization of Process Parameters in Plasma Arc C...vivatechijri
This paper presents an experimental investigation on the optimization and the effect of the cutting
parameters on Material Removal Rate (MRR) in Plasma Arc Cutting (PAC) of EN-45A Material using Taguchi L
16 orthogonal array method. Four process variables viz. cutting speed, current, stand-off-distance and plasma
gas pressure have been considered for this experimental work. Analysis of variance (ANOVA) has been performed
to get the percentage contribution of each process parameter for the response variable i.e. MRR. Based on
ANOVA, it has been observed that the cutting speed, current and the plasma gas pressure are the major
influencing factors that affect the response variable. Confirmation test based on optimal setting shows the better
agreement with the predicted values.
This document presents a study comparing laser cutting and plasma cutting of mild steel E350 material. The study aims to select the best cutting technology and investigate the effects of process parameters on output responses. Laser power, cutting speed, and gas pressure were varied as input parameters, while surface roughness, kerf, taper, and heat affected zone were measured as output responses. Experiments were conducted according to a Taguchi L27 design of experiments. Analysis of variance found that all input parameters significantly affected the output responses. Laser cutting produced lower surface roughness and taper compared to plasma cutting for the material. Optimal parameters for laser cutting of mild steel were identified.
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
This document discusses using the Taguchi method to optimize WEDM parameters for machining EN 31 steel to achieve lower surface roughness. An experiment was conducted using an L9 orthogonal array to test different levels of pulse on time, pulse off time, gap voltage, and wire feed. Analysis of variance showed that pulse on time had the largest effect on surface roughness at 48.84%, followed by gap voltage at 36.81%. Confirmation experiments found that the optimized parameters of 4μs pulse on time, 6μs pulse off time, 40V gap voltage, and 4mm/min wire feed achieved a predicted surface roughness with only 11.5% error, validating the model. The Taguchi method was able to effectively optimize
IRJET- Parametric Optimization of Tig Welding on SS 304 and MS using Tagu...IRJET Journal
The document discusses optimizing TIG welding parameters for joining stainless steel 304 and mild steel using the Taguchi method. The parameters investigated were current, voltage, and gas flow rate. Specimens were welded based on an L9 orthogonal array. Tensile testing and hardness testing were conducted to evaluate weld strength and quality. Signal-to-noise ratios were calculated and ANOVA was used to determine the influence of each parameter. The results showed that current had the greatest influence on tensile strength, followed by gas flow rate, with voltage having the least influence. The optimal parameters for maximizing tensile strength were determined to be a current of 250A, voltage of 24V, and gas flow rate of 14 L/
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
This document summarizes a study on optimizing electric discharge machining (EDM) parameters to maximize material removal rate (MRR) and minimize electrode wear rate (EWR) when machining stainless steel 316 with a copper electrode. Experiments were conducted using a Taguchi design of experiments with four machining parameters (pulse on time, pulse off time, current, fluid pressure) each at three levels. Results showed that pulse off time and current had the most significant effects on MRR and EWR, respectively. Specifically, MRR increased with longer pulse off times while EWR decreased at higher currents. The optimal settings found were a current of 12 amps and long pulse off time to achieve maximum MRR during EDM of
IRJET- Effects of Process Parameters in Wire Cut EDM on Material Removal Rate...IRJET Journal
This document summarizes a study that investigated the effects of process parameters in wire cut electrical discharge machining (WEDM) on the material removal rate of aluminum composite materials. Experiments were conducted varying parameters like pulse on time, pulse off time, servo voltage, and wire speed. It was found that material removal rate increased with increasing pulse on time and decreased with increasing pulse off time and servo voltage. The optimal set of parameters to maximize material removal rate was also determined.
IRJET- Experimental Investigation and Optimization of Wear Characteristics of...IRJET Journal
The document experimentally investigates the optimization of wear characteristics of brass metal matrix composite reinforced with molybdenum disulphide using Taguchi technique. Brass composite samples with 2%, 4%, and 6% molybdenum disulphide by weight were fabricated using stir casting. Pin-on-disc tests were conducted to analyze the wear rate while varying percentage reinforcement, load, temperature, and sliding velocity. Taguchi design of experiments was used to determine the optimal levels of parameters that minimize wear rate. Analysis of variance found that applied load had the greatest influence on wear rate, followed by percentage reinforcement and temperature. A regression model was developed that correlates the input parameters to wear rate.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Realizing Potential of Graphite Powder in Enhancing Machining Rate in AEDM of...IDES Editor
Additive mixed electric discharge machining
(AEDM) is a recent innovation for enhancing the capabilities
of electrical discharge machining process. The objective of
present study is to realize the potential of graphite powder as
additive in enhancing machining capabilities of AEDM on
Inconel 718. Taguchi methodology has been adopted to plan
and analyze the experimental results. L36 Orthogonal Array
has been selected to conduct experiments. Peak current, Pulse
on time, duty cycle, gap voltage, retract distance and
concentration of fine graphite powder added into the dielectric
fluid were chosen as input process variables to study
performance in terms of material removal rate. The ANOVA
analysis identifies the most important parameters to maximize
material removal rate. The recommended best parametric
settings have been verified by conducting confirmation
experiments. From the present experimental study it is found
that addition of graphite powder enhances machining rate
appreciably. Machining rate is improved by 26.85% with 12g/
l of fine graphite powder at best parametric setting.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
Abstract: In this investigation, experimental work and computational work are combined to obtain improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time (Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are fed to the Minitab software and optimum input parameters for the desired output parameters are identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is performed in order to remove the recast layer and again the surface roughness is measured by using stylus type roughness tester. Finally from the obtained results it was found that there was significant improvement in the Surface roughness of the nickel alloy material. In addition using regression analysis this work is stimulated by computational method and the results are obtained
This document provides an overview of a project that aims to compare the effectiveness of the Taguchi method and Shainin design of experiments (DOE) technique for optimizing surface roughness. The objectives are to compare the two methods and determine the applicability of the Taguchi method. The problem statement indicates the adoption of experimental design techniques can help a company improve cost and quality. The literature review discusses perspectives on the relative power and validity of different approaches. The methodology section indicates Taguchi and Shainin DOE approaches will be followed. The expected result is to identify optimum parameters for surface roughness measurement using the techniques and compare their effectiveness.
Taguchi Method is a new engineering design optimisation methodology that improves the quality of existing products and processes and simultaneously reduces their costs very rapidly, with minimum engineering resources and development man-hours
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
MULTIOBJECTIVE OPTIMIZATION OF MACHINING PARAMETERSFOR C-65 MATERIAL USING TA...AVINASH JURIANI
CNC machines lead a major in a manufacturing industry, machining comprises of wide variety of operations with turning operation being the most important one. In turning operation performance specifications of concern include surface
finish, material removal rate& tolerance which are mostly affected by different
machining parameters like machining condition, work piece, tool geometry and
operating parameters. Among all of them operating parameter and tool
geometry is the most important parameter for better surface finish. This
project presents the optimization of various operating parameters as velocity,
feed and depth of cut for proper selection of tool inserts for surface finish. The
experiment was conducted on CNC lathe with C-65 shaft material. Taguchi’s
statistical analysis was employed for single optimization as it provides an
effective method for product designing which operate continuously over
varying conditions surface roughness and depth of cut is the most effective
parameter for material removal rate. Best parameter combinations for
optimum surface roughness are speed (A) at level 2 (191 m/min), feed (B)
at level 1 (0.2 mm/rev), depth of cut (C) at level 3 (1.5 mm), for optimum
material removal rate are speed (A) at level 3 (254 m/min), feed (B) at level 3
(0.3 mm/rev), depth of cut (C) at level 3 (1.5 mm). GRG optimum
parameters for SR and MRR are Speed (A) at level 2 (191 m/min), feed (B)
at level 1 (0.2 mm/rev), depth of cut (C) at level 3 (1.5 mm)
Optimization of Process Parameters of Powder Mixed Dielectric EDM for MRR and RaIRJET Journal
This document presents an experimental study on optimizing process parameters for powder mixed dielectric electric discharge machining (PMEDM) to maximize material removal rate (MRR) and minimize surface roughness (Ra). Taguchi methodology was used to design experiments using an L9 orthogonal array with discharge current, duty factor, spark gap, and graphite powder concentration as input variables. Regression analysis and grey relational analysis were conducted on the experimental results. The optimal parametric combination found was discharge current of 20A, duty factor of 5%, spark gap of 0.05mm, and graphite powder concentration of 6g/l, achieving a predicted MRR of 68.43mm3/min and Ra of 7.28μm,
This document summarizes a study that used the Taguchi method to analyze the effect of parameters like voltage, current, and pulse on time on material removal rate (MRR) and surface roughness (SR) during CNC EDM of SK-5 material. Experiments were conducted based on an L9 orthogonal array with 3 factors at 3 levels. Analysis found voltage had the largest effect on MRR while pulse on time most influenced SR. The optimized parameters were experiment 4 for MRR and experiment 7 for SR. In conclusion, the Taguchi method helped determine the best settings of CNC EDM parameters for machining SK-5.
Experimental Investigations to Study the Impact of Machining Parameters on Mi...IJERA Editor
Plasma arc cutting is extensively used to cut steels and aluminum. Plasma arc cutting was invented in 1950‟s and since then, it became commercial on its advent into the industry. The purpose of this research is to ascertain the influence of various parameters on plasma arc cutting process while machining mild steel. The experiments were conducted using Taguchi L16 orthogonal array with current, voltage, speed, plate thickness as the control parameters and surface roughness, kerf as the response variables. The optimal parameter setting for the machining process is determined by conducting a Grey-Taguchi method. Orthogonal array L16 (4 power 4) of Taguchi, Signal to Noise ratio, the Analysis of Variance(ANOVA) are employed to find the optimal levels and to analyze the optimum levels and to analyze the impact of current, voltage, speed, plate thickness on kerf and surface roughness.
IRJET- Experimental Investigation for Effect of Vibration on Mechanical Prope...IRJET Journal
This document investigates the effect of vibration on the mechanical properties of Duplex Stainless Steel (DSS) 2205 during Tungsten Inert Gas (TIG) welding. Nine experimental welds were conducted using parameters of welding current, torch tilt angle, and vibration motor speed based on Taguchi's design of experiments. Tensile strength and hardness were evaluated for each weld. Results showed that applying vibration during welding increased tensile strength and hardness compared to welding without vibration. The optimal parameters were a welding current of 80 amps, torch tilt angle of 90 degrees, and vibration motor speed of 1500 RPM, which produced a weld with the highest tensile strength of 855 MPa. In conclusion,
The document discusses the implementation of the Taguchi method to optimize process parameters for maximizing the material removal rate (MRR) in electrical discharge machining (EDM). Key process parameters analyzed include peak current, pulse on time, pulse off time, tool material, and workpiece material. Experiments were conducted using a Taguchi L27 orthogonal array with three levels for each parameter. Analysis of variance of the signal-to-noise ratios revealed that current has the most significant effect on MRR, followed by pulse on time, pulse off time, and tool material. The optimal parameters determined for maximum MRR were a peak current of 20A, pulse on time of 8μs, pulse off time of 5μs, using
Experimental Analysis and Optimization of Process Parameters in Plasma Arc C...vivatechijri
This paper presents an experimental investigation on the optimization and the effect of the cutting
parameters on Material Removal Rate (MRR) in Plasma Arc Cutting (PAC) of EN-45A Material using Taguchi L
16 orthogonal array method. Four process variables viz. cutting speed, current, stand-off-distance and plasma
gas pressure have been considered for this experimental work. Analysis of variance (ANOVA) has been performed
to get the percentage contribution of each process parameter for the response variable i.e. MRR. Based on
ANOVA, it has been observed that the cutting speed, current and the plasma gas pressure are the major
influencing factors that affect the response variable. Confirmation test based on optimal setting shows the better
agreement with the predicted values.
This document presents a study comparing laser cutting and plasma cutting of mild steel E350 material. The study aims to select the best cutting technology and investigate the effects of process parameters on output responses. Laser power, cutting speed, and gas pressure were varied as input parameters, while surface roughness, kerf, taper, and heat affected zone were measured as output responses. Experiments were conducted according to a Taguchi L27 design of experiments. Analysis of variance found that all input parameters significantly affected the output responses. Laser cutting produced lower surface roughness and taper compared to plasma cutting for the material. Optimal parameters for laser cutting of mild steel were identified.
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
This document discusses using the Taguchi method to optimize WEDM parameters for machining EN 31 steel to achieve lower surface roughness. An experiment was conducted using an L9 orthogonal array to test different levels of pulse on time, pulse off time, gap voltage, and wire feed. Analysis of variance showed that pulse on time had the largest effect on surface roughness at 48.84%, followed by gap voltage at 36.81%. Confirmation experiments found that the optimized parameters of 4μs pulse on time, 6μs pulse off time, 40V gap voltage, and 4mm/min wire feed achieved a predicted surface roughness with only 11.5% error, validating the model. The Taguchi method was able to effectively optimize
IRJET- Parametric Optimization of Tig Welding on SS 304 and MS using Tagu...IRJET Journal
The document discusses optimizing TIG welding parameters for joining stainless steel 304 and mild steel using the Taguchi method. The parameters investigated were current, voltage, and gas flow rate. Specimens were welded based on an L9 orthogonal array. Tensile testing and hardness testing were conducted to evaluate weld strength and quality. Signal-to-noise ratios were calculated and ANOVA was used to determine the influence of each parameter. The results showed that current had the greatest influence on tensile strength, followed by gas flow rate, with voltage having the least influence. The optimal parameters for maximizing tensile strength were determined to be a current of 250A, voltage of 24V, and gas flow rate of 14 L/
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
This document summarizes a study on optimizing electric discharge machining (EDM) parameters to maximize material removal rate (MRR) and minimize electrode wear rate (EWR) when machining stainless steel 316 with a copper electrode. Experiments were conducted using a Taguchi design of experiments with four machining parameters (pulse on time, pulse off time, current, fluid pressure) each at three levels. Results showed that pulse off time and current had the most significant effects on MRR and EWR, respectively. Specifically, MRR increased with longer pulse off times while EWR decreased at higher currents. The optimal settings found were a current of 12 amps and long pulse off time to achieve maximum MRR during EDM of
IRJET- Effects of Process Parameters in Wire Cut EDM on Material Removal Rate...IRJET Journal
This document summarizes a study that investigated the effects of process parameters in wire cut electrical discharge machining (WEDM) on the material removal rate of aluminum composite materials. Experiments were conducted varying parameters like pulse on time, pulse off time, servo voltage, and wire speed. It was found that material removal rate increased with increasing pulse on time and decreased with increasing pulse off time and servo voltage. The optimal set of parameters to maximize material removal rate was also determined.
IRJET- Experimental Investigation and Optimization of Wear Characteristics of...IRJET Journal
The document experimentally investigates the optimization of wear characteristics of brass metal matrix composite reinforced with molybdenum disulphide using Taguchi technique. Brass composite samples with 2%, 4%, and 6% molybdenum disulphide by weight were fabricated using stir casting. Pin-on-disc tests were conducted to analyze the wear rate while varying percentage reinforcement, load, temperature, and sliding velocity. Taguchi design of experiments was used to determine the optimal levels of parameters that minimize wear rate. Analysis of variance found that applied load had the greatest influence on wear rate, followed by percentage reinforcement and temperature. A regression model was developed that correlates the input parameters to wear rate.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Realizing Potential of Graphite Powder in Enhancing Machining Rate in AEDM of...IDES Editor
Additive mixed electric discharge machining
(AEDM) is a recent innovation for enhancing the capabilities
of electrical discharge machining process. The objective of
present study is to realize the potential of graphite powder as
additive in enhancing machining capabilities of AEDM on
Inconel 718. Taguchi methodology has been adopted to plan
and analyze the experimental results. L36 Orthogonal Array
has been selected to conduct experiments. Peak current, Pulse
on time, duty cycle, gap voltage, retract distance and
concentration of fine graphite powder added into the dielectric
fluid were chosen as input process variables to study
performance in terms of material removal rate. The ANOVA
analysis identifies the most important parameters to maximize
material removal rate. The recommended best parametric
settings have been verified by conducting confirmation
experiments. From the present experimental study it is found
that addition of graphite powder enhances machining rate
appreciably. Machining rate is improved by 26.85% with 12g/
l of fine graphite powder at best parametric setting.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
Abstract: In this investigation, experimental work and computational work are combined to obtain improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time (Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are fed to the Minitab software and optimum input parameters for the desired output parameters are identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is performed in order to remove the recast layer and again the surface roughness is measured by using stylus type roughness tester. Finally from the obtained results it was found that there was significant improvement in the Surface roughness of the nickel alloy material. In addition using regression analysis this work is stimulated by computational method and the results are obtained
This document provides an overview of a project that aims to compare the effectiveness of the Taguchi method and Shainin design of experiments (DOE) technique for optimizing surface roughness. The objectives are to compare the two methods and determine the applicability of the Taguchi method. The problem statement indicates the adoption of experimental design techniques can help a company improve cost and quality. The literature review discusses perspectives on the relative power and validity of different approaches. The methodology section indicates Taguchi and Shainin DOE approaches will be followed. The expected result is to identify optimum parameters for surface roughness measurement using the techniques and compare their effectiveness.
Taguchi Method is a new engineering design optimisation methodology that improves the quality of existing products and processes and simultaneously reduces their costs very rapidly, with minimum engineering resources and development man-hours
Design of Experiment (DOE): Taguchi Method and Full Factorial Design in Surfa...Ahmad Syafiq
Taguchi and full factorial design techniques to highlight the application and to compare the effectiveness of the Taguchi and full factorial design processes as applied on surface
roughness.
Dorian Shainin was an American quality consultant and engineer notable for developing the "Red X" concept for industrial problem solving and product reliability. Shainin tools provide a simplified approach to Design of Experiments to logically identify root causes of variation. The key Shainin tools are Iso Plot, Multivari, Component Search and Variable Search, Group Comparison, and Precontrol (stoplight control). Shainin referred to root causes as "Red X" primary causes, "Pink X" secondary causes, and "Pink-Pink X" minor but still controllable causes.
PREPERATION OF METAL WORKING FLUID FROM CASTOR OIL & PERFORMANCE ANALYSIS BY ...Alagappapandian M
This document describes the preparation and performance analysis of a metal working fluid made from castor oil using the Taguchi method. The objectives are to increase machining performance while producing a more environmentally friendly fluid. Castor oil and additives are emulsified to produce the fluid. An L9 orthogonal array experimental design is used to test varying machining parameters like speed, feed rate, and depth of cut. Analysis of surface roughness and tool/workpiece weight changes indicates the optimized parameters provide good surface quality and metal removal rate. The Taguchi method and vegetable oil-based fluid help improve machining operation and quality at low cost in an eco-friendly way.
The document discusses the Taguchi Method, an approach to quality engineering developed by Genichi Taguchi. It was used to improve postwar telephone systems in Japan. The method focuses on designing quality into products and services from the beginning to eliminate non-random errors. It quantifies quality losses using quality loss functions and aims to reduce sources of variation. The document outlines the Taguchi experiment process, which involves identifying problems, designing experiments, running tests, analyzing results, and confirming improvements. It recommends using expert help to fully apply the method to services.
Optimization of wedm process parameters using taguchi methodDharam Deo Prasad
This document describes optimizing the parameters of a wire electrical discharge machining (WEDM) process using the Taguchi method and grey-based Taguchi method. It introduces WEDM and its components/process. Key parameters investigated are pulse-on time, pulse-off time, wire feed, and gap voltage. Experiments are conducted using Taguchi's orthogonal array design and the grey-based Taguchi method is applied to optimize the parameters for maximizing material removal rate and minimizing surface roughness and kerf width. Confirmation experiments show improved machining efficiency with the optimized parameters.
Optimization of EDM process parameters for machining SS310IRJET Journal
This document discusses optimizing process parameters in electrical discharge machining (EDM) of stainless steel SS310. A study was conducted using Taguchi's design of experiments to optimize discharge current and spark gap to increase material removal rate and decrease tool wear rate. Experiments were performed with copper as the tool material and SS310 as the workpiece. The results found that discharge current had the greatest influence on both material removal rate and tool wear rate, with higher currents increasing material removal rate and tool wear rate. The optimal parameters were determined to be a higher discharge current to maximize material removal rate.
Electrical Discharge Drilling of micro-hole on Inconel 718 using Rotary Tubul...JibinOommen2
- This paper investigates drilling micro-holes in Inconel 718 using rotary tubular electrode micro EDM drilling. Experiments were conducted varying peak current, pulse-on time, and pulse-off time.
- The results showed that peak current has the dominant effect on material removal rate, while pulse-on time most influences hole taper. The diameter overcut was within 20% of the tool diameter.
- Based on the Taguchi analysis, the order of importance of the process parameters from most to least influential were found to be current, pulse-on time, and pulse-off time. The paper concludes that the experimental method can effectively drill micro-holes in difficult-to-machine Inconel
Electrical Discharge Drilling of micro-hole on Inconel 718 using Rotary Tubul...JibinOommen2
This paper aims to investigate the effect of μ-EDM process parameters on Material Removal Rate (MRR), Hole Taper and Diameter over cut on Inconel-718 material using rotating electrode
The document describes an experiment to optimize bead geometry parameters for bead-on-plate welds produced by submerged arc welding (SAW) using Taguchi's design of experiments method. Welding current, voltage, speed, and nozzle distance were varied at five levels in an L25 orthogonal array to produce 25 welds. Bead geometry responses like reinforcement height, penetration depth, and width were measured. Analysis of variance was used to determine the most influential parameters on responses. The optimal parameter combination was identified and confirmed with additional testing, achieving the goal of multi-response optimization of bead geometry for SAW welds.
Optimization of Process Parameters of Wire Electrical Discharge Machining of ...IRJET Journal
This document summarizes a study that used the Taguchi method to optimize the process parameters for wire electrical discharge machining (WEDM) of EN31 steel. The parameters examined were pulse on time, pulse off time, peak current, and wire tension. Experiments were conducted based on an L9 orthogonal array to evaluate the effects of the parameters on machining time and surface roughness. The optimal parameter combinations for minimizing machining time were found to be pulse on time at the third level, pulse off time at the second level, peak current at the third level, and wire tension at the second level. The optimal parameters for minimizing surface roughness were pulse on time at the second level, pulse off time at the second level, peak
This document discusses optimizing wire electrical discharge machining (WEDM) process parameters using the Taguchi method and grey relational analysis. It describes WEDM, the process parameters tested, and the Taguchi experimental design used. The document outlines the steps of the grey-based Taguchi method applied, including calculating signal-to-noise ratios for responses, determining the optimal levels of factors, and comparing results from tables and graphs. Charts show the main effects of varying pulse on time, pulse off time, and peak current on material removal rate, electrode consumption, and surface roughness.
Parametric Optimization of Wire Electrical Discharge Machining (WEDM) Process...theijes
The document describes an experiment to optimize cutting parameters for wire electrical discharge machining (WEDM) of titanium grade 5 alloy. Experiments were conducted using a Taguchi L25 orthogonal array to investigate the effects of pulse on time, pulse off time, peak current, wire tension, servo voltage, and servo feed rate on material removal rate and surface roughness. The experiments found that pulse on time, pulse off time, and peak current were the most significant factors influencing the performance measures. Analysis of the experimental results using signal-to-noise ratios identified the optimal machining parameters to maximize material removal rate while minimizing surface roughness.
The document describes an experiment to optimize cutting parameters for wire electrical discharge machining (WEDM) of titanium grade 5 alloy. Experiments were conducted using a Taguchi L25 orthogonal array to investigate the effects of pulse on time, pulse off time, peak current, wire tension, servo voltage, and servo feed rate on material removal rate and surface roughness. The experiments found that pulse on time, pulse off time, and peak current were the most significant factors influencing the performance measures. Analysis of the experimental results using signal-to-noise ratios identified the optimal machining parameters to maximize material removal rate while minimizing surface roughness.
Cutting Parameter Optimization for Surface Finish and Hole Accuracy in Drilli...IOSR Journals
This document describes a study that used Taguchi's design of experiments methodology to optimize cutting parameters for surface finish and hole accuracy in drilling of EN-31 material. Experiments were conducted varying speed, feed rate, drill depth, and tool type. Response variables of surface roughness and hole diameter error were measured. Analysis of variance and regression analysis were used to determine the significant factors and develop models. For surface finish, speed of 30m/min, feed of 0.2mm/rev, and HSS tool were found to be optimal. For hole accuracy, optimal settings were 30m/min speed, 0.2mm/rev feed, HSS+TiN tool, and 20mm drill depth.
This document describes an experiment conducted to optimize cutting parameters for surface finish and hole accuracy in drilling of EN-31 material. The researchers used Taguchi's design of experiments methodology to determine the optimal levels for speed, feed rate, tool type, and drill depth. For surface finish, speed of 30m/min, feed rate of 0.2 mm/rev, and HSS tool type were found to be optimal. For hole accuracy, optimal levels were 30m/min speed, 0.2 mm/rev feed rate, HSS+TiN tool type, and 20mm drill depth. Analysis of variance and regression analysis supported the findings. The results provide guidance to industries on parameters to achieve good surface finish and accuracy during
INFLUENCE OF PROCESS PARAMETERS ON SURFACE ROUGHNESS AND MATERIAL REMOVAL RAT...ijmech
This document summarizes an experimental study that investigated the effects of machining parameters on surface roughness and material removal rate during CNC turning. 32 experiments were conducted varying depth of cut, spindle speed, and feed rate according to a mixed Taguchi design of experiments. The results found that feed rate had the strongest influence on surface roughness, while material removal rate depended most on spindle speed and depth of cut. Artificial neural networks were also used to model the relationships between input parameters and output responses. Analysis of variance confirmed that all input factors significantly affected the responses according to the developed regression models.
PROCESS PARAMETERS OPTIMIZATION IN EDM FOR AISI D3 STEEL BY GREY RELATIONAL A...ijiert bestjournal
In this work,optimization problem for AISI D3 mate rial has been solved to satisfy requirements of productivity in EDM operation.Experiments on di e sinking EDM have been conducted using L16 orthogonal array design using various process c ontrol parameters like discharge current(Ip),pulse on time(Ton),pulse off time(Toff)and spar k gap(SG)which are varied in four different levels.Material Removal Rate(MRR)and surface rou ghness(Ra)has been measured for each experimental run.Problem has been formulated in ma ximization of MRR(in order to increase productivity)and minimization of Ra.Taguchi metho d is used for Design of experiment.Optimum values of process parameters are obtained u sing grey relational analysis method.
Investigating the effect of machining parameters on surface roughnessIAEME Publication
This document summarizes a study that used Design of Experiments (DOE) and Analysis of Variance (ANOVA) to investigate the effects of machining parameters on the surface roughness of 6061 aluminum alloy during end milling. The parameters examined were cutting speed, depth of cut, and feed rate. The study found that feed rate had the most significant impact on surface roughness based on ANOVA results. The optimal parameters for a smooth surface were a cutting speed of 500 rpm, depth of cut of 1.2 mm, and feed rate of 15.33 mm/min.
This document summarizes a study that used the Taguchi method to optimize electrical discharge machining (EDM) parameters for material removal rate (MRR) and electrode wear rate (EWR) in machining EN36 alloy steel. Experiments were conducted using an L9 orthogonal array with four parameters (pulse on time, pulse off time, current, and voltage) each at three levels. Analysis of variance showed current had the greatest effect on MRR while conformational tests identified the optimal parameters as pulse on time of 100 μs, pulse off time of 12 μs, current of 14 A, and voltage of 40 V. A similar process was followed to analyze EWR, with current also having the greatest impact based on ANOVA.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Plasma arc cutting parameters using taguchi methodchiragkolambe
In this paper, we have tested on a plasma arc
cutting machine but by using the Taguchi method. This
machine is accurate, high finishing. This process is very
cheap than another process like laser cutting. In the market,
this process has a high demand. In this paper, we will go to
study the Cutting Speed and Arc Gap and another import
factor in this process are using the Taguchi method by using
Minitab 17. We went Analysis Taguchi Analysis: surface
roughness, kerf versus speed, ... ideas, air gap. By using this
method ANOVO we will find General Linear Model: surface
roughness versus speed, ... ides, air gap In this research we
will use Mild Steel E350
Optimization of Process Parameters for Deep Hole Drilling using Drill EDM for...IRJET Journal
The document discusses optimizing process parameters for deep hole drilling using electric discharge machining (EDM) on tungsten carbide. Experiments were conducted using a copper electrode to drill holes in tungsten carbide. The parameters of discharge current, pulse on time, and pulse off time were optimized using Taguchi methods to maximize machining rate and minimize electrode wear ratio. Grey relation analysis was used to determine a single optimized set of parameters that considers both responses. The optimal parameters found were a discharge current of 6A, pulse on time of 6μs, and pulse off time of 5μs.
Optimization of Machining Parameters During Micro Milling Process on PTFE Mat...IRJET Journal
This document summarizes research optimizing machining parameters during micro milling of polytetrafluoroethylene (PTFE) material. Experiments were conducted using a Taguchi L9 orthogonal array to examine the effects of cutting speed, feed rate, and depth of cut on material removal rate, cutting forces, and dimensional deviation. Analysis of variance found feed rate was the most significant factor influencing material removal rate, while depth of cut most influenced one cutting force component and feed rate another. Overall, the optimal parameters were found to be a speed of 900 rpm, feed of 90 mm/min, and depth of cut of 0.05 mm for minimizing forces and deviations.
Parametric Study of Multi-Spot Welded Lap Shear Specimen for Shear StrengthIJERA Editor
The effect of number of spots, spot spacing, squeezing force, welding current, weld time , overlapping length
and sheet thicknesson the shear strength of two similar galvanized steel sheets are investigated through
experiments using RSM method. Similar sheets of galvanized steel sheets are made by resistance spot welding
at different processing conditions and these joint populations were tested under lap-shear loading conditions.
Specially fabricated fixture is used to load the lap shear specimen in the universal testing machine Regression
analysis is done to obtain relationship between shear strength and selected parameters. The experimental results
indicate that the failure loads of spot welds in lap-shear specimens increase when number of spot, squeezing
force, welding current and sheet thickness increase for the given ranges.
Experimental Study and Optimisation of Mrr In CNC Plasma ARC CuttingIJERA Editor
The research and development in the precise and accurate machining technology of hard metals (Ferrous, non-ferrous and glass etc) is gaining much importance in the industry since last many years. Due to the tremendous competition and cost factor, the non-conventional machining technology is becoming the first choice of the engineers and technicians. In this era of advanced technological processes the CNC plasma arc machining is gaining tremendous ground in the industry. It is much more capable of producing best finished, high accurate machining of very complicated non-symmetrical profile in no time. The main objective and targets of this practical experiment is based to achieve the best possible setting and parameters of operation on a CNC plasma arc machine to achieving speedy work i.e. Maximum material removal rate.
Similar to Implimentation of Taguchi method on CNC EDM and CNC WEDM (20)
3. A
B
S KEYWORDS: CNC EDM, CNC
WEDM, Taguchi method, DOE,
T Orthogonal array
R
A
C
T
4. INTRODUCTION
C DESIGN OF EXPERIMENT
O
TAGUCHI METHOD
N
EXPERIMENTRAL AND SLECTION
T OF PROCESS PARAMETERS
E EXPERIMENTRAL OBSERAVATION
N EXPERIMENTRAL RESULTS AND
ANALYSIS TAGUCHI METHOD
T
CONCLSIONS
REFERENCES
5. INTRODUCTION
EDM is an electro-thermal non-
traditional machining
process, where electrical energy
is used to generate electrical
spark and material removal
mainly occurs due to thermal
energy of the spark
The work material is
removed by a series of sparks
that cause localized melting
and evaporation of the
material
EDNC 32H MAKINO high precision CNC
EDM
6. EDM is mainly used to machine difficult-to-
machine materials.
The electrode is made from electrically conductive
material.
EDNC 32H MAKINO high precision CNC EDM
Dielectric fluid should be nonconductor of electricity
7. WIRE CUT ELECTRO
DISCHARGE MACHINING
(WEDM),
WEDM is electro-thermal
mechanisms to cut electrically
conductive material.
WEDM has become the
essential part of many
manufacturing process
industries, which need variety,
precision and accuracy
FA10S MITSUBISHI high precision CNC
WEDM
8. DESIGN OF EXPERIMENT
Design of Experiments (DOE) refers to planning, designing
and analyzing an experiment so that valid and objective
conclusions can be drawn effectively and efficiently.
The input variables are called Factors and the output
variables are called Response.
9. THE ADVANTAGES OF DESIGN OF
EXPERIMENTS ARE
Numbers of trials is significantly reduced.
Optimal setting of the parameters can be found
out.
Qualitative estimation of parameters can be made.
Experimental error can be estimated.
Inference regarding the effect of parameters on
the characteristics of the process
10. Dr. Genichi
Taguchi was
DR. GENICHI TAGUCHI Born in Japan,
1924. He is an
Electrical
Engineer and
Worked during
1950’s to
improve Japan’s
post-WWII
telephone
communication
system And also
called Father of
the
“Taguchi
Method” and
“Robust
Engineering
11. HE SUGGESTED THAT
THE DESIGN PROCESS
SHOULD BE SEEN AS
THREE STAGES
• SYSTEM DESIGN
1
• PARAMETER
2 DESIGN
• TOLERANCE
3 DESIGN
In this present work, the Taguchi method has been used to
plan the experiments for parameter design and subsequent
analysis of the data collected
12. PARAMETER DESIGN
Parameter design determines the most appropriate,
optimizing set of parameters identifying the settings of
each parameter which will minimize variation from the
target performance
The selection of control factors (parameters) and their
“OPTIMAL” levels
The objective is to make the
“IMPROVEMENT OF QUALITY”
The “ OPTIMAL ” parameter levels can be determined
through experimentation
15. EXPERIMENTRAL AND SLECTION OF PROCESS
PARAMETERS FOR CNC EDM
INPUT FACTORS FOR CNC EDM
1) VOLTAGE (V)
2) CURRENT (I)
3) PULSE ON TIME (TON)
RESPONSES MEASURED FOR EDM
1) MATERIAL REMOVAL RATE (MRR),
2) MACHINING TIME
16. TABLE 1:- LEVEL VALUES OF INPUT FACTOR
Symbols Testing parameters Level1 Level2 Level3
A Voltage (V) 6 7 5
B Current(I) 2 3 4
C Pulse ON time(Ton) 35 40 45
Array Selector
17. ORTHOGONAL ARRAYS
Orthogonal Arrays represent a versatile class of
combinational arrangements useful for conducting
experiments.
The standard two level and three level arrays are:
•Two level arrays: L4, L8, L12, L16, L32
•Three level arrays: L9, L18, L27
19. SLECTION OF MATERIAL FOR EDM OF ALLOY
STEEL(SK-5) MATERIAL HAS BEEN CONSIDER USING
COPPER ELECTRODE
Dia Of Electrode :
9.4mm
20.
21.
22. EXPERIMENTRAL OBSERAVATION & CALCULATION
OF VARIOUS RESPONSE FACTORS BASED ON
TAGUCHI L9 ORTHOGONAL ARRAY
PARAMETER LEVELS MACHI MACHI MRR 1 MRR2
EXP VOLTA CURRE PULSE NING NIG In In
NO GE NT ON TIME 1 TIME 2 mm3/sec mm3/sec
TIME In secs In secs
1 6 2 35 92 94 0.2008 0.1511
2 6 3 40 79 83 0.2426 0.1994
3 6 4 45 45 43 0.3281 0.3097
4 7 2 40 38 34 0.2962 0.3036
5 7 3 45 49 46 0.3321 0.3416
6 7 4 35 69 70 0.2097 0.1987
7 5 2 45 68 67 0.2434 0.2247
8 5 3 35 96 97 0.1352 0.1359
9 5 4 40 73 70 0.1864 0.1805
23. SIGNAL TO NOISE RATIO
Taguchi's emphasis on minimizing deviation from target
led him to develop measures of the process output that
incorporate both the location of the output as well as the
variation. These measures are called signal to noise ratios.
The signal to noise ratio provides a measure of the impact
of noise factors on performance.
24. There are 3 Signal-to-Noise ratios of common
interest for optimization of Static Problems
SMALLER- NOMINAL- LARGER-
THE-BETTER THE-BEST THE-BETTER
NOMINAL-THE-BEST
n = 10 Log10 [ square of mean/ variance ]
This case arises when a specified value is MOST desired,
meaning that neither a smaller nor a larger value is desirable
25. CALCULATION OF SIGNAL TO NOISE RATIO FOR
MRR AND MT
PARAMETER LEVELS SN SN
EXP NO VOLTAGE CURRENT PULSE ON RATIO for RATIO for
TIME MT MRR
1 6 2 35 36.3594 13.8276
2 6 3 40 29.1388 18.0704
3 6 4 45 29.8588 28.4448
4 7 2 40 22.0952 36.8242
5 7 3 45 27.0017 45.1361
6 7 4 35 39.8500 29.1000
7 5 2 45 39.5964 24.8895
8 5 3 35 42.7008 26.5849
9 5 4 40 30.5540 53.5758
26. Response Table for Signal to Noise Ratios for MT
LEVEL VOLTAGE IN V CURRENT IN PULSE ON
AMP TIME
1 37.6162 32.6788 39.6364
2 31.7912 32.9521 27.2640
3 29.6429 33.4194 32.1499
Δ 7.9733 0.7406 12.3724
RANK 2 3 1
Therefore, PULSE ON TIME has the maximum effect on MACHINING
TIME
27. Response Table for Signal to Noise Ratios for MRR
LEVEL VOLTAGE IN CURRENT IN PULSE ON
V AMP TIME
1 35.02 25.18 23.17
2 20.11 29.93 36.16
3 37.02 37.04 32.82
Δ 16.91 11.86 12.99
RANK 1 3 2
Therefore VOLTAGE has the largest effect on MATERIAL
REMOVAL RATE.
28. SIMILARLY (WEDM) OF AL-6061 MATERIAL HAS
BEEN CONSIDER USING WEDM WITH A BRASS WIRE
ELECTRODE
29.
30. EXPERIMENTRAL AND SLECTION OF PROCESS
PARAMETERS FOR CNC EDM
Input Factors:- Responses measured:-
Voltage (v) Machining time (MT),
Cutting speed (CS)
Current (Ip)
Voltage gap (Vg)
Wire tension (WT)
LEVEL VALUES OF INPUT FACTORS
Symbols Testing parameters Level1 Level2 Level3
A Voltage (V) 6 8 10
B Current(I) 4 7 9
C Voltage gap (Vg) 55 58 60
D Wire tension (WT) 8 9 10
31. EXPERIMENTAL RESULTS AND CALCULATIONS OF VARIOUS
RESPONSE FACTORS BASED ON TAGUCHI L9 ORTHOGONAL
ARRAY
Calculation of Signal to Noise ratio for MT
EXP PARAMETER LEVELS MT1 MT2 SN
NO In sec In sec RATIO
VOLTAGE CURRENT VOLTAGE WIRE
(V) (I) GAP (VG) TENSION
(WT)
1 6 4 55 8 12.54 12.07 31.3683
2 6 7 58 9 8.02 7.58 27.9796
3 6 9 60 10 15.20 14.54 30.0635
4 8 4 58 10 12.36 12.10 36.4588
5 8 7 60 8 6.57 6.54 49.7993
6 8 9 55 9 2.52 2.40 29.2427
7 10 4 60 9 12.46 12.01 31.6966
8 10 7 55 10 3.31 3.17 30.2966
9 10 9 58 8 3.02 2.50 17.4697
32. CALCULATION OF SIGNAL TO NOISE RATIO FOR CS
EXP PARAMETER LEVELS CS1 CS2 SN RATIO
NO VOLTAGE CURRENT VOLTAGE GAP WIRE TENSION In mm/sec In
(V) (I) (VG) (WT) Mm/sec
1 6 4 55 8 1.3 1.32 39.3348
2 6 7 58 9 1.7 1.89 22.5043
3 6 9 60 10 0.5 1.27 3.3082
4 8 4 58 10 1.1 1.40 15.3430
5 8 7 60 8 2.9 2.46 18.6745
6 8 9 55 9 5.6 6.18 23.1335
7 10 4 60 9 1.3 1.34 33.3795
8 10 7 55 10 4.6 4.89 27.2830
9 10 9 58 8 5.4 6.10 21.2855
33. RESPONSE TABLE FOR SIGNAL TO NOISE RATIOS FOR MT
LEVEL VOLTAGE IN CURRENT IN VOLTAGE WIRE
V AMP GAP TENSION
1 29.8038 33.1745 30.3025 32.8791
2 38.5002 36.0251 27.3027 29.6396
3 26.4876 25.5919 37.1864 32.2729
Δ 12.0126 10.4332 9.8837 3.2395
RANK 1 2 3 4
RESPONSE TABLE FOR SIGNAL TO NOISE RATIOS FOR CS
LEVEL VOLTAGE IN CURRENT VOLTAGE WIRE
V IN AMP GAP TENSION
1 21.7157 29.3524 29.9171 26.4316
2 19.0503 22.8206 19.7109 26.3391
3 27.316 15.9090 18.4540 15.3114
Δ 8.2657 13.4434 11.4631 11.1202
RANK 4 1 2 3
34. CONCLUSION FOR CNC EDM
The MACHINING TIME (MT) mainly affected by
PULSE ON TIME, VOLTAGE has less effect on it.
Current (I) has a least effect on MT.
The MATERIAL REMOVAL RATE (MRR) is mainly
influenced by VOLTAGE, The effect of PULSE ON TIME
is less and Current has least effect on it.
Exp no. 4 is the OPTIMIZED PARAMETER for MT
Exp no. 1 is the OPTIMIZED PARAMETER for MRR
35. CONCLUSION FOR CNC WEDM
The MACHINING TIME (MT) mainly affected by
VOLTAGE , CURRENT &VOLTAGE GAP has less
effect on it. WIRE TENSION has a least effect on MT
The CUTTING SPEED (CS) is mainly influenced by
CURRENT, The effect of VOLTAGE GAP ,WIRE
TENSION is less and VOLTAGE has least effect on it.
Exp no. 9 is the OPTIMIZED PARAMETER for MT
Exp no. 3 is the OPTIMIZED PARAMETER for CS
36. REFERENCES
Abbas, N.M., Solomon, D.G., Bahari, M. F. (2007), “A
review on current research trends in electrical discharge
machining (EDM)”, International Journal of Machine Tools
& Manufacture, 47, 1214–1228.
Adler, Yu. P., Markova, E.V., Granovsky, Yu.V. (1975),“The
design of experiments to find optimal conditions”, Mir
Publishers, Moscow.
Pandey P C , Shan H S, Modern Machining Processes, Tata
McGraw-Hill publishing Company Limited, New Delhi,
(1999).
Phadke M.S, Quality Engineering Using Robust Design,
Prentice- Hall, Englewood Cliffs,NJ, (1989).